Rounnd Design Alkaline Electrolyzer

Rounnd Design Alkaline Electrolyzer

Alkaline electrolysers are typically composed of electrodes, a microporous separator and an aqueous alkaline electrolyte of approximately 30.
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Product Introduction
Your Leading SANY Hydrogen Energy Co., Ltd. Supplier
 

Focusing on the R&D, manufacturing and sales of hydrogen producing and refueling equipment and key components for a closed-loop full ecological industrial chain featured by green power, hydrogen energy and end-use equipment, SANY Hydrogen Energy Co., Ltd. is the world's leading provider of package solutions for hydrogen energy equipment, which is committed to providing global customers with GW-level ultra-large-scale package solutions on-grid/off-grid hydrogen production from wind and solar energy.

 

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What is Round Design Alkaline Electrolyzer?

 

 

Alkaline electrolysers are typically composed of electrodes, a microporous separator and an aqueous alkaline electrolyte of approximately 30.

 

 
Benefits of Round Design Alkaline Electrolyzer
 
01/

High efficiency: Alkaline electrolysis has a high efficiency for converting electrical energy into hydrogen gas. The efficiency can be as high as 80%, which means that 80% of the electrical energy input can be converted into hydrogen gas.

02/

Scalability: Alkaline electrolysis can be scaled up or down depending on the size of the hydrogen production facility needed. This makes it suitable for a wide range of applications, from small-scale hydrogen production for fuel cells to large-scale industrial hydrogen production.

03/

Renewable energy source: Alkaline electrolysis can be powered by renewable energy sources such as wind and solar power, making it a clean and sustainable way to produce hydrogen.

04/

High-purity hydrogen: Alkaline electrolysis produces high-purity hydrogen gas, which is suitable for a wide range of applications, including fuel cells and chemical production.

05/

Low operating costs: Alkaline electrolysis is relatively inexpensive to operate, as it does not require expensive catalysts or high temperatures to operate. This makes it an attractive option for hydrogen production, especially in areas with low electricity costs.

06/

Safe and environmentally friendly: Alkaline electrolysis does not produce any greenhouse gas emissions or other harmful pollutants, making it a safe and environmentally friendly way to produce hydrogen.

 

Application of Round Design Alkaline Electrolyzer

Feedstock:
Hydrogen is widely used as a feedstock in various industries and sectors and serves as a key component in the production of chemicals, in refineries, steel manufacturing and power generation. Producing Hydrogen through alkaline water electrolysis enables these industries to decarbonise.

Chemical industry:
Hydrogen is a crucial feedstock, serving as a building block for the synthesis of a variety of chemical compounds and used in the production of ammonia, methanol, hydrogen peroxide and various organic compounds.

Refineries:
Hydrogen is utilised in refineries for hydroprocessing, where it is combined with heavy petroleum fractions to remove impurities and improve the quality of fuel products.

Steel production:
Hydrogen is employed in the iron and steel industry as a feedstock to reduce iron ore in to metallic iron in a process called direct reduction. This reduces carbon emissions associated with traditional production processes.

Power generation:
Hydrogen can be used as a feedstock for power generation through the utilisation of fuel cell technologies, which convert hydrogen in to electricity, usable as a clean energy source.

Mobility:
The use of hydrogen in mobility applications facilitates the transition to low-carbon transportation and the reduction of greenhouse gas emissions. It offers the advantage of providing a clean and sustainable energy source for a wide range of vehicles and transportation methods such as buses, trucks, taxis, personal cars, and even trains and ships. Hydrogen fuel cell vehicles enable longer range and quicker refuelling times when compared to battery electric vehicles, crucially also reducing weight.

Fuel:
By converting renewable electricity into hydrogen through alkaline water electrolysis, hydrogen as a fuel can be stored and transported over long distances, buffering and balancing the intermittent nature of renewable electricity supplies. This fuel can then be used for power generation, steam production or even to replace natural gas in domestic heating applications.

 

 
 
Main Differences Between Alkaline Electrolyzers and Other Types of Electrolyzers

There are several key differences between alkaline electrolyzers and other types of electrolyzers, including:

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Electrolyte

Alkaline electrolyzers use a liquid potassium hydroxide (KOH) electrolyte, whereas other types of electrolyzers use solid polymer electrolytes or acidic electrolytes.

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Efficiency

Alkaline electrolyzers have a higher energy efficiency than other types of electrolyzers, meaning they require less energy to produce a given amount of hydrogen.

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Operating temperature

Alkaline electrolyzers operate at higher temperatures than other types of electrolyzers, typically between 70°C and 100°C.

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Hydrogen purity

Alkaline electrolyzers can produce high-purity hydrogen without the need for additional purification steps.

 

 

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What Are the Operating Conditions for Alkaline Electrolyzers?

The alkaline water electrolyzer typically operates at ∼60–80 °C with a corresponding thermodynamic voltage for water splitting of 1.20–1.18 V. The terminal cell voltage of an alkaline water electrolyzer is 1.8–2.4 V at the typical operational current density of 0.2 to 0.4 A cm−2.

 

Operating principles of Alkaline Electrolyzers

 

An alkaline electrolyzer is a device that uses an electrolyte solution, typically potassium or sodium hydroxide, to split water molecules into hydrogen and oxygen through a process called electrolysis. The chemical principle behind an alkaline electrolyzer is based on the principles of electrochemistry. In electrochemistry, chemical reactions are driven by the transfer of electrons from one substance to another. When an electrical current is applied to an electrolyte solution, it causes the electrolyte solution to undergo a process called electrolysis. During this process, the electrical current causes the water molecules to be split into their constituent atoms of hydrogen and oxygen.

In an alkaline electrolyzer, the process is made possible by the presence of the electrolyte solution, which contains hydroxide ions (OH-) that facilitate the transfer of electrons between the electrodes and the water molecules. The hydroxide ions are attracted to the positively charged anode (the electrode connected to the positive terminal of the power source) and the hydrogen ions (H+) are attracted to the negatively charged cathode (the electrode connected to the negative terminal of the power source).

● At the anode, water molecules are oxidized to form oxygen gas and positively charged hydrogen ions: 2H2O → O2 + 4H+ + 4e-
● At the cathode, hydrogen ions are reduced to form hydrogen gas: 4H+ + 4e- → 2H2
● Overall, the reaction can be expressed as: 2H2O → 2H2 + O2

The electrolyte solution plays an important role in the process by providing a conductive medium for the flow of electrons between the electrodes and the water molecules. The hydroxide ions in the electrolyte solution also help to maintain a stable pH level, which is important for the efficient functioning of the electrolyzer.

 

Electrocatalyst Development for Alkaline Water Electrolysis

 

 

The activity of the electrocatalyst depends on several physicochemical properties of the material, including the composition, conductivity, electronic and crystal structures, morphology and textural parameters, as well as the preparation method, grain boundaries, surface structure, and the presence of defects. The performance of the electrocatalyst can be boosted either by increasing the number of active sites on a given electrode, through enhanced loading or altering structural properties to expose more catalytic active sites per gram, or manipulating the intrinsic activity of each active site by keeping the mass constant. The catalyst materials must fulfill some basic requirements and criteria to be considered for large-scale applications. On the one hand, it should be efficient and provide a high current density at low applied potential, should have good structural durability and stability under operating conditions, and should be cost-effective. On the other hand, the figure of merit of the catalyst should be holistic and take into account other key aspects during the electrocatalyst design including sustainability, criticality (covering supply and geopolitical risks of raw materials), ecology, and recyclability. It is very essential to prioritize sustainability and recyclability in every stage of production, considering the limited resources and depletion of many elements in the near future. It is also worth noting that the electrocatalytic performance of a catalyst is highly dependent on the experimental conditions and measurement techniques. For a more detailed understanding of electrocatalytic properties and performance indicators, as well as a protocol for evaluating the activity and stability of OER catalysts, one can refer to other review articles.

 

Why Is the Part Load Limit Range of Alkaline Water Electrolysers Spanning 10% to 25%?
 

This is related to the management of the alkaline electrolyte: either through separate circuits for the oxygen and hydrogen streams or through a common path.

The mixture of gas and electrolyte for each electrode is always routed separately to separators to extract most gas but some residual gas (intended gas and impurities) remains embedded in the liquid. If the electrolyte streams leaving the separators are mixed before being fed back to each electrode, there is a mixing of residual gases and an increase in residual hydrogen on the oxygen-producing side as well as an increase in residual oxygen on the hydrogen-producing side, thereby increasing contamination level and imposing a shutdown at a higher load. This setup would typically call for a shutdown near the 25% limit.

Keeping the electrolyte streams independent after the separators prevents such added contamination and pushes the safety limit closer to the 10% load limit. However, this solution comes with its own drawbacks: water consumption on the hydrogen-producing side (cathode) increases electrolyte concentration, while water production on the oxygen-producing side (anode) decreases electrolyte concentration. Some liquid level balancing and electrolyte concentration balancing is still required to maintain pumping capability (liquid level) and optimal electrolyte concentration (electrolyser efficiency depends on electrolyte conductivity). For example, using NaOH as electrolyte, peak conductivity is ~65 S/m at 50°C and reached for a concentration just below 20%mas, while using KOH, peak conductivity is ~95 S/m at 50°C and reached for a concentration just above 30%mas.

 

Our Factory

 

Focusing on the R&D, manufacturing and sales of hydrogen producing and refueling equipment and key components for a closed-loop full ecological industrial chain featured by green power, hydrogen energy and end-use equipment, SANY Hydrogen Energy Co., Ltd. is the world's leading provider of package solutions for hydrogen energy equipment, which is committed to providing global customers with GW-level ultra-large-scale package solutions on-grid/off-grid hydrogen production from wind and solar energy.

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FAQ

 

Q: How does an alkaline Electrolyser work?

A: Alkaline electrolyzers operate via transport of hydroxide ions (OH-) through the electrolyte from the cathode to the anode with hydrogen being generated on the cathode side.

Q: What is the difference between alkaline electrolyser and PEM electrolyser?

A: The key difference between an alkaline electrolyser and a proton exchange membrane electrolyser (PEM) is what ion diffuses between the anode and cathode side of the cell. In an alkaline electrolyser, alkaline OH- ions diffuse. In a PEM electrolyser, protons, H+ ions, diffuse.

Q: What is the lifespan of an alkaline electrolyzer?

A: Currently, AEC is the most developed electrolyzer and also has the lowest capital cost (1000–5000 $/kW varying with scale [80]). The stack lifetime of AEC can reach as long as 60,000–90,000 h (7–10 years).

Q: Which electrolyzer is best for hydrogen production?

A: Solid oxide electrolysis cell (SOEC) electrolysers - SOECs differ as they utilise heat to make hydrogen from steam and are best placed where there is a heat source available (nuclear or industrial facilities). They operate at high temperatures (500 - 850 ℃).

Q: How much does an alkaline electrolyzer cost?

A: Alkaline electrolyzers are generally considered to have the lowest cost per kW in commercial scale plants (over 2MW), on the order of $800 to $1000 per kW– which works out to $1.8 to $2.25 million USD per tonne of daily capacity (based on 55kWh per kg hydrogen production).

Q: Why is hydrogen electrolysis so expensive?

A: But creating hydrogen and transforming it into a useful format requires energy - and that energy is not necessarily renewable. That process is also inefficient and expensive compared with other forms of energy, renewable or not.

Q: What is the voltage of an alkaline electrolyzer?

A: The voltage of the conventional electrolyzer is 2V, and the current density is 3000A/㎡, while the new electrolyzer HELA2000/HELA2000Plus can reach the current density of 4300A/㎡ under the voltage of 1.92V in the small chamber.

Q: How efficient is alkaline electrolyzer system?

A: Efficiency and gas purity
Industrial size alkaline electrolysers have an efficiency of 65+% (up to 67%) and produce hydrogen with a gas purity of 99.5+%vol (up to 99.9%vol). They generally operate between 60 and 90°C with a current density of 0.2 to 0.4 A/cm2, leading to a stack lifetime of 60.000 to 90.000 h .

Q: How much energy does alkaline electrolysis consume?

A: The production capacity of these industrial electrolysers is in the 5–500 m3 H2/h range. NEL electrolysers operate at atmospheric pressure and deliver 50–485 m3 H2/h with energy consumption in the range 4.1–4.3 kWh/H2 Nm3 at current densities up to 0.3 A/cm2.

Q: How can I speed up electrolysis?

A: Efficiency is increased through the addition of an electrolyte (such as a salt, an acid or a base) and electrocatalysts.

Q: What are the problems with alkaline electrolyzers?

A: One disadvantage of alkaline water electrolyzers is the low performance profiles caused by the commonly-used thick diaphragms that increase ohmic resistance, the lower intrinsic conductivity of OH− compared to H+, and the higher gas crossover observed for highly porous diaphragms.

Q: Can electrolyzers use salt water?

A: Researchers led by the University of Adelaide School Of Chemical Engineering have successfully developed a green hydrogen electrolysis system that directly uses saltwater at nearly 100% efficiency.

Q: What is the minimum load of alkaline electrolyzers?

A: 10 to 40%
For alkaline electrolyzers this minimum load varies from 10 to 40% [6] and is primarily determined by the volume fraction of hydrogen in oxygen (HTO).

Q: How efficient is alkaline electrolyzer system?

A: Efficiency and gas purity
Industrial size alkaline electrolysers have an efficiency of 65+% (up to 67%) and produce hydrogen with a gas purity of 99.5+%vol (up to 99.9%vol). They generally operate between 60 and 90°C with a current density of 0.2 to 0.4 A/cm2, leading to a stack lifetime of 60.000 to 90.000 h .

Q: What is the output pressure of alkaline electrolyser?

A: The schematic of an alkaline electrolyzer is shown in figure 1. A cell frame, electrolyte, anode and cathode electrode, and separating diaphragm are the major components of an alkaline electrolyzer. It can operate in pressure ranging from 1-30 bars and has an operating temperature of 60-80°c.

Q: What are the applications of alkaline electrolyzer?

A: The applications of alkaline electrolyzer are classified into standalone large-scale hydrogen production systems and the additional system as means of a hybrid system for energy recovery applications. A hydrogen production capacity of 1,374,142 kg/year was obtained by adopting wind energy during the off-grid hours.

Q: What is the water quality required for alkaline electrolysis?

A: It's well known that the water supplied to the electrolyser must be of high purity. Commercial electrolyser manufacturers typically specify a minimum required water supply quality in terms of conductivity, typically <1 μS cm−1 (>1 MΩ cm),12 and a total organic carbon (TOC) content.

Q: What is the current density limit for alkaline water electrolysis?

A: A nominal current density of 1.8 A cm−2 seems achievable for alkaline electrolysis. To enable a minimum load of 10%, the pressure is preferably kept below 8 bara. Gas crossover is mainly driven by diffusive hydrogen transport. Supersaturation at the diaphragm interface plays an important role.

Q: Why is high pressure electrolysis better than alkaline electrolyzer?

A: PEM electrolyzers are more efficient than alkaline electrolyzers, but they are also more expensive. PEM electrolyzers operate at high current densities and can produce hydrogen at high pressures, making them well-suited for applications such as refueling vehicles and powering fuel cells.

Q: What is the maintenance of electrolysers?

A: The main regular maintenance needed is draining and refilling electrolyte once a year or if the electrolyte quality is degraded. The used electrolyte needs to be disposed according to the local regulations. It should be checked that the ventilation ports are free of dust and obstacles and that there are no leakages.

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